Semester 1
Module Introduction
ENGR5002 Design & Practice II
Dr Shpend Gerguri
Reader in Engineering Design
Faculty of Technology, Design and Built Environment
School of Engineering, Computing & Mathematics (R2.30)
Content
Module handout & timetable
Group work requirements - Screw Pump Project!
Assessment strategy (including peer review)
Engineering Design Process & Design Specification
Practical session – Group formations!
2
Overview
The module(s) will be taught by Shpend Gerguri (SG) & Andrew Bradley (AB) and
Mary Matthew (MM). Students studying Mechanical Engineering, Automotive,
Motorsport Engineering, Robotic Engineering, Electro Mechanical
There are three elements to the module:
i) Engineering Design and CAD/CAM/FEA taught by SG (all students)
ii) Control and instrumentation labs (MM)
ii) Auto/Motorsport aspects taught by AB (all students)
To begin with, everybody is in together and SG will teach engineering design,
CAE (using SolidWorks & HSMWorks CAD/CAM). Teaching on this will continue
over both semesters. Semester 2 will also cover Finite Element Analysis.
In week 6 in S1 we will start with Computer Aided Manufacture (CAM).
Week 10-12 Control and Instrumentation labs with MM.
3
Assessment strategy
The assessment for this double module is 100% coursework.
All students 50% Design/CAE/Control
50% Vehicle Design assignment in FEA
--------
100%
In order to pass this compulsory module a minimum of 40% is required.
Each lecturer will provide details of the assessment they are offering during the
course of the module.
4
Semester 1 plan of work
Week 1: Introduction, group project and design specification.
Week 2: Pump Project (design & manufacturing issues), ‘O’ rings, BS4518.
Week 3: Limits, Fits
Week 4: Geometric Dimensioning and Tolerance (GDT applied to Screw pump).
Week 5: Progress meetings - feedback session.
Week 6: Application and Selection of Bearings I, 2D Machining and Turning.
Week 7 : Application and Selection of Bearings II, High Speed 3D Machining.
Week 8 : FMEA and Advanced 3D Machining
Weeks 9: Costing (prototype)
Week 10-12 : Control, Motors and Sensors (Arduino sessions & water pump labs)
Seminars
Weeks 5-12: Seminar sessions (Group work on Screw Pump project, 2D detailed
drawing preparations, Limits and Fits, GDT, Surface finishes, bearing and
seals, costing, CAM instructions and group report preparation for submission)
5
Semester 1 Timetable
Lectures/Seminar:
All: 09.00 - 11.00am, every Wednesday in JHBG20.
Practicals:
11.00am -14.00pm, every Wednesday (Set A room AB115)
(Set B, room AB115)
(Set C, room AB115)
12.00pm -1.00pm, every Friday (Set D, room G116)
6
GROUP DESIGN PROJECT
7
Group design work – Screw Pump Project (PBL)
Individual/team effort (max. 6 students per group).
Groups formed in week 1 during the practical sessions.
Week 1-5: Solid modelling and assembly of “faulty” pump.
Week 6: Peer review of engineering drawings (BS8888)
Week 2-12: Improve/redesign “faulty” pump.
Week 5 - progress meeting with each group (concepts).
January 2023: Submit group design report (10/01/2025)
Peer assessments weeks 4, 8, 12
8
“Faulty” pump
9
“Faulty” pump
10
“Faulty” pump
Gaskets
Nuts &
Bolts
Seals
CFD Analysis:- water
flow through the
system Bearings
U04526 / U04527 11
CAD modelling skills and techniques (wk 1-4)
More complex
such as the
inlet
Simple
component
such as gasket Screw rotor,
using advanced
modelling
techniques.
U04526 / U04527 12
Engineering Design Process
GATHER
INFORMATION
DESIGN
CLIENT Engineering DESIGN SPECIFICATION
NEED PROBLEM
View
CONCEPT
GENERATION
DETAILED
DESIGN
MANUFACTURE
AND SELL
Pugh – Total Design (1990)
U04526 / U04527
13
Screw Pump Project -weekly tasks (see p8)
Effort
Task Week Individual Team
1.
Project brief & form working groups. Produce a Gantt 1-2 x x
chart for Semester 1 tasks.
2.
Complete Design Specification, tabulate design 2-3 x x
deficiencies of the ‘faulty’ pump.
3.
Concept generation of proposed design improvements 3-4 x x
and concept selection.
4.
Progress meeting and submit improved drawings of the 5-6 x x
‘faulty’ pump that conform to BS8888 drawing standards.
5.
CAD model(s) of the selected concept. 5-6 x x
6.
2D Manufacturing drawings, limits & fits, GDT, bearings 6-10 x x
and seals, overall prototype cost.
7.
FMEA & CAM of redesigned pump part(s) 8-12 x x
8.
Submit Group Report (10/01/2025) Jan 2025 x x
9.
Peer Assessment intervals wks (individual contribution) 4,8,12 x x
U04526 / U04527
14
Past Examples of Pump Project
Rendered CAD model
U04526 / U04527
15
Functional Analysis diagram
U04526 / U04527
16
Concept Sketches
U04526 / U04527
17
Concept Sketches
U04526 / U04527
18
Concept Sketches
U04526 / U04527
19
Selection matrix
U04526 / U04527
20
2D Engineering drawings
U04526 / U04527
21
2D Engineering drawings
U04526 / U04527
22
Assembly/Exploded view etc
U04526 / U04527
23
Prototype cost (BOM)
U04526 / U04527
24
Example – Semester 2
U04526 / U04527
25
Example – Semester 2
U04526 / U04527
26
Example – Semester 2
U04526 / U04527
27
Example – Semester 2
U04526 / U04527
28
Example – Semester 2
U04526 / U04527
29
Example – Semester 2
U04526 / U04527
30
Example – Semester 2
U04526 / U04527
31
Assessment
50 % of the total module mark (including instrumentation and control) will be
allocated for producing a 3D CAD model of your proposed design solution of the
screw pump. This will include marks for application of engineering design
theory/solutions, producing 2D detailed engineering drawings for each part, CAM
instructions and assembly drawings as necessary in the form of a design report. For
detailed marking scheme see pages 12-13 in the project brief.
Break down
- Introduction (aim and objectives) 5%
- Project managemet (Gantt chart etc) 5%
- Concept generation/selection 15%
- Engineering theory 20%
- Costing 10%
- FMEA, Engineering drawings & CAM 40%
- Report presentation 5%
Total 100%
Peer Assessment
Assess contribution of each individual in the group (average value; wks 4, 8 and 12).
Take as an example a group of four members for a report mark of 62%.
For an equal share of work all the members have contributed 25%.
Contribution Report mark 50% Report 50% Report
Group Member Total
(%) mark fwd mark scl.
(conditional)
Tom 31*(20/25)
20 62 31 55.8
=24.8
Dick 31*(30/25)
30 62 31 68.2
=37.2
Harry 31*(15/25)
15 62 31 49.6
=18.6
Lucy 31*(35/25)
35 62 31 74.4
=43.4
Total
100% -- -- -- --
Peer Assessment – cont.
Tom receives half the report mark carried forward (i.e 31%), and his individual
contribution was only 20%.
Given that there were four members in the group, a fair contribution would have
been 25%.
Therefore, the other half of the report mark is scaled accordingly (i.e he receives
(20/25)*half the report mark). The marks are then added together to give a final
grade of 55.8%
Similarly
Harry receives a mark of 31 + [(15/25)*31] = 49.6 %
NOTE: In the instances where there may be a big discrepancy, a cap will be applied
to reflect the overall quality of the work produced.
Group work – minutes of the meetings
Group work (requires individual & team effort)
Meetings outside the class hours
Take minutes of the meetings
- what is to be done?
- by whom?
- responsibilities?
- deadlines, actions
Keep a record using template shown on page 11 in the project brief.
Submit them as part of your report.
Engineering Alumni – Joshua Shires
(www.mous.co)
Finally…whatever you design remember this
Simplicity is often the mark of a good design,
the fewest parts needed to complete the job in
hand….it often becomes the cheapest and the
most reliable solution to the problem
NSS Thematic comments (MEng/BEng) ENGR5002
Comments were analysed and Course content was the most popular
theme within the positive comments such as “The second year Design
and Practice projects were great, where you learn the most about
actually being an engineer.
Finally…whatever you design remember this
‘We should not expect the end user (customer) to compensate for flawed
designs’
